EP2716979B1

EP2716979B1 - Infrared device and manufacturing method thereof

Info

Publication number: EP2716979B1
Application number: EP12788740.4A
Authority: EP
Inventors: Tianyi LUO; Yingzhi Wang
Original assignee: X&N (Zhongshan) Gas Technology Stock Co Ltd
Current assignee: X&N (Zhongshan) Gas Technology Stock Co Ltd
Priority date: 2011-05-26
Filing date: 2012-05-25
Publication date: 2019-01-09
Anticipated expiration: 2032-05-25
Also published as: EP2716979A1; CN102798123B; BR112013029989A2; AU2016262643B2; WO2012159589A1; CN102798123A; RU2600801C2; MX2013013898A; US9625148B2; JP2014517244A; US20140080079A1; EP2716979A4; AU2012261367B2; MX363078B; AU2012261367A1; AU2016262643A1; JP6023798B2; KR20140013065A; RU2013156777A

Description

FIELD OF THE INVENTION

The invention relates to an infrared device for use in a burner and a method for manufacturing the same, and more particularly to an infrared deviceapplied to a fully premixed burner for infrared conversion and radiation heating, as well as a method for manufacturing the same.

BACKGROUND OF THE INVENTION

With the energy shortage and increasing severity of the environmental pollution, countries all over the world advocate to develop energy saving products, and thus more and more energy saving products have appeared.
Conventional gas appliancesutilize mainly an atmospheric burner, which heats the target mainly by physical convection. This heating mode results in a large amount of chemical and physical thermal loss. For example, in China, the standard for the thermal efficiency ofan atmospheric burnerused in a household embedded stove is preset as only 50%. In fact, the maximum thermal efficiency of the atmospheric burner does not exceed 55%. To improve the thermal efficiency in gas appliances, the chemical and physical thermal lossesduring the combustion process must be reduced. However, the existing combustion mode limits the improvement of the thermal efficiency in the atmospheric burners.
Chinese Patent Application No. 200510035410.0 , titled by "infrared metal honeycomb burner used in gas appliances and preparation method thereof", discloses a highly efficient burning device. The burning device is applied to a burner and can transform the ordinary physical and chemical thermal energy into infrared radiation energy. The thermal energy is transferred to the heating object in the form of infrared radiation. This heating mode effectively reduces the physical and chemical thermal losses, and achieves the technical requirements of saving energy and low emission. The thermal efficiency of the burner in the invention exceeds 68%, and the emissions of CO and NO_X are far below the Chinese national standard, thus completely solving the problems of low thermal efficiency and low infrared radiation of gas appliances.
However, in practice, a portion of metal bands of the infrared burner is apt to protrude due to the frequent alternation of high and low temperature, which causes the deformation and axial movement of the honeycomb body, thereby affecting the normal use of the burner. Further infrared devices for burners are known from CN201170553Y , JP09170725 and NL1005992A4 .

SUMMARY OF THE INVENTION

In view of the above-described problems, it is one objective of the invention to provide an infrared device for use in a burner and a preparation method thereof to solve the problems of deformation and axial movement of metal bands of a honeycomb body resulting from the alternation between high and low temperatures.
To achieve the above objective, an infrared device for use in a burner according to claim 1 and a method for manufacturing the said device according to claim 9 are provided.
As an example outside the scope of the invention, there is described an infrared device for use in a burner, comprising a honeycomb body formed by laminating or coiling a metal band. The honeycomb body comprises a plurality of holes. The honeycomb body has a first surface A and a second surface B which are opposite to each other, and a lateral surface connecting an outer boundary of the first surface A and an outer boundary of the second surface B. The holes penetrate through the first surface A and the second surface B. A through hole is disposed on the lateral surface of the honeycomb body and penetrates inward through multiple layers of adjacent metal bands, and a metal wire is disposed in the through hole for fixing the metal bands.
The invention provides for an infrared device for use in a burner, comprising a honeycomb body (10) being in the shape of a cylinder; the honeycomb body (10) comprising a metal band; said metal band being laminated or coiled to yield a plurality of holes; said honeycomb body (10) further comprising a top surface ((14), surface A) and a bottom surface ((15), surface B) which are opposite to each other; said plurality of holes penetrating through said top surface (14) and said bottom surface (15); and an outer boundary of said top surface (14) and an outer boundary of said bottom surface (15) being connected whereby yielding a lateral surface (16); and said metal band comprises a flat band (11) and a corrugated band (13); said flat band (11) comprises a plurality of folding portions; said flat band (11) is connected to said corrugated band (13); said plurality of folding portions is folded onto said top surface (14) and/or said bottom surface (15); and each of said plurality of folding portions overlaps an adjacent one of said plurality of folding portions to form an overlapping embedded member (60).
For the above-mentioned infrared devices, the honeycomb body is formed by laminating or coiling the metal band, and the honeycomb body comprises the through hole and the metal wire disposed in the through hole, or the embedded member disposed on the first and/or second surface. Thus, the manufacturing process of the devices is simple; the resulting devices have low production cost, and can prevent the deformation and axial movement of the metal bands due to the frequent alternation between high temperature and low temperature.
As an improvement, a space formed by embedding the laminated or coiled metal bands is filled with a metal material, and the metal material is fixed on the laminated or coiled metal bands by welding or bonding. Thus, the deformation of the honeycomb and axial movement of the metal bands are further prevented, and the disadvantage factortargeting the combustion gas resulting from the embedding of the embedded member is also removed due to the filling of the metal material.
As an improvement, the embedded member is fixed by self-melting and welding of the laminated or coiled metal bands. This fixation mode can also prevent the deformation of the honeycomb and axial movement of the metal bands.
As an improvement, the metal band employs an integrated metal band comprising two corrugated metal bands, and the holes or gaps are formed between the two corrugated metal bands, or an integrated metal band comprising a corrugated metal band and a smooth metal band.
As an improvement, the first surface A and/or the second surface B of the honeycomb body is covered with a metal mesh, and a contact point between the honeycomb body and the metal mesh is fixed by welding.
As an improvement, the first surface A and/or the second surface B of the honeycomb body is covered with a metal fiber structure, the metal fiber structure is breathable and presents in the form of fiber mesh, fiber felt, woven mesh, or fiber paper, and a contact point between the honeycomb body and the metal fiber structure is fixed by welding.
The arrangement of the metal mesh or the metal fiber structure improves the combustion characteristics and stability of the device.
For the above mentioned device outside the scope of the invention there is knwon a preparation method thereof, the method comprising:

A) preparing the metal band;
B) laminating or coiling the metal band to form the honeycomb body comprising the plurality of holes; and
C) disposing the through hole on the lateral surface 16 of the honeycomb body, allowing the through hole to penetrate inward through multiple layers of adjacent metal bands, and disposing the metal wire in the through hole for fixing the metal bands.

For the infrared device for use in a burner according to the invention a preparation method is provided, the method comprising the following steps: a) preparing said metal band; b) laminating or coiling said metal band to form said honeycomb body (10) comprising the plurality of holes; and c) folding said plurality of folding portions onto said top surface (14) and/or said bottom surface (15), and engaging each of said plurality of folding portions with an adjacent one of said plurality of folding portions to form said overlapping embedded member (60).
The first surface A and the second surface B in the invention refer to a gas inlet surface and a gas outlet surface, respectively.
Advantages of the invention will be given below accompanying detailed description thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a stereogram of an infrared device for use in a burner in outside the scope of the invention;
FIG. 2 is an exploded view of an infrared device for use in a shown in FIG. 1;
FIG. 3 is a stereogram of an infrared device for use in a burner in accordance with an embodiment of the invention;
FIG. 4 is a local enlarged view of an embedded memberas shown in FIG. 3;
FIG. 5 is a plan view of a honeycomb body outside the invention, where the honeycomb body is formed by laminating corrugated metal bands;
FIG. 6 is a plan view of a honeycomb body as shown in FIG. 5 which comprises a lateral surface encircled by a metal frame;
FIG. 7 is a stereogram of an infrared device for use in a burner comprising an embedded memberas shown in FIG. 2, where the embedded member is filled with metal wire for welding;
FIG. 8 is a stereogram of an infrared device for use in a burner comprising an embedded member as shown in FIG. 2, where the embedded member is fixed by self-melting and welding;
FIG. 9 is a stereogram of a honeycomb body covered with metal meshes on both sides;
FIG. 10 is an exploded view of a honeycomb body covered with metal meshes on both sides;
FIG. 11 shows a coil method to prepare a honeycomb body comprising a central hole; and
FIG. 12 shows a method to prepare an integrated metal band comprising a corrugated metal band and a smooth metal band.

DETAILED DESCRIPTION OF THE EMBODIMENTS

For further illustrating the invention, experiments detailing an infrared device for use in a burner and a preparation method thereof are described below. It should be noted that the following examples are intended to describe and not to limit the invention.
Detailed description of the invention will be given below in conjunction with accompanying FIGS. 1-8.

Example 1

As shown in FIGS. 1-2, an infrared device applied to a gas appliance, comprises a honeycomb body 10. The honeycomb body 10 comprises a metal band and a plurality of holes which are formed by laminating or coiling the metal band. The honeycomb body 10 has a first surface A 14 and a second surface B 15 which are opposite to each other, and a lateral surface 16 connecting an edge of the first surface A and an edge of the second surface B. A through hole 50 is disposed on the lateral surface of the honeycomb body and penetrates inward through multiple layers of adjacent metal bands, and a metal wire 51 is disposed in the through hole 50 for fixing the metal bands.
In this example, the through hole 50 and the metal wire 51 disposed in the through hole 50 constitute a special fixed structure. Conventional infrared honeycomb body is apt to expand and deform due to the frequent alternation between high and low temperatures, which causes the deformation and axial movement of the honeycomb body. The arrangement of the special fixed structure can effectively prevent the deformation and axial movement of the metal bands of the honeycomb body.
As an improvement, the holes are round, oval, semi-circular, or polygonal in shape. In contrast to elongated gaps, the hole having the above shapes has better combustion characteristics.
As an improvement, a central hole 12 having a diameter of between 2 and 300 mm is disposed in the middle of the honeycomb body 10 to operate as an air flow channel. The airflow channel allows the fuel gas to mix with the air again to ensure a complete combustion.
As an improvement, to enhance the overall structural strength of the honeycomb, the central hole 12, the lateral surface 16, or the both are encircled by a metal frame 20 or 30 whereby fixing the honeycomb body.
As an improvement, to ensure the fixation of the metal wire 51, preferably, at least one end of the metal wire 51 is fixed on the wire band or the metal frame 20 or 30.
It should be noted that although the honeycomb 10 is formed by laminating the metal band, it is not limited to this, the honeycomb can also be formed using other methods, for example, by coiling the metal band.

Example 2

As shown in FIGS. 3-4, an infrared device applied to a gas appliance, comprises a honeycomb body 10. The honeycomb body 10 comprises a metal band and a plurality of holes or gaps which are formed by laminating or coiling the metal band. The honeycomb body 10 has a first surface A 14, i. e. a top surface (14), and a second surface B 15 .i.e. bottom surface (15), which are opposite to each other, and a lateral surface 16 connecting an edge of the first surface A and an edge of the second surface B. A part of the metal band on the first surface A and/or the second surface B are embedded, overlapped and engaged with adjacent metal bands to form an overlapping embedded member 60.
The overlapping embedded member 60 arranged on part of the first surface A and/or the second surface B can effectively prevent the expansion and deformation due to the frequent alternation between high and low temperatures, thereby preventing the deformation and axial movement of the metal bands of the honeycomb body. Additionally, in contrast to the infrared device in Example 1, the infrared device of this example has a simple process, thereby saving the production costs.
As described in Example 1, although the honeycomb 10 is formed by laminating the metal band, it is not limited to this, the honeycomb can also be formed using other methods, for example, by coiling the metal band.
To ensure the fixation of the embedded structure, as shown in FIG. 7, a space formed by embedding the metal bands may be filled with a metal material 61, and the metal material is fixed on the metal bands by welding.
Preferably, the overlapping embedded member is formed on some of the metal bands close to the edge of the honeycomb body.When the overlapping embedded member is disposed where the protrusion is most likely to occur, fewer embedded members can achieve better deformation resistance effect.
Preferably, the embedded member intersects with all the metal bands of the honeycomb body. Such an arrangement of the overlapping embedded member simplifies the manufacturing process of the infrared device.
Preferably, the overlapping embedded member is Y-shaped, with an outward opening. The Y-shaped embedded member can prevent the congestion thereof in the center of the honeycomb body.
Preferably, as shown in FIG. 8, the embedded member 60 is formed and fixed by self-melting and welding of the metal bands.
Preferably, the embedded member 60 can be disposed on the first surface A and/or the second surface B. If the embedded member 60 is disposed on the first surface A, upon combustion, the infrared device can display patterns that cannot be displayed during nonuse.
To ensure a complete combustion and the overall structural strength of the honeycomb 10,a central hole 12 having a diameter of between 2 and 300 mm is disposed in the middle of the honeycomb body 10 to operate as an airflow channel, and the central hole 12, the lateral surface 16, or the both are encircled by a metal frame 20 or 30.
Preferably, the metal bands employ a corrugated metal band 13, or an integrated metal band comprising a corrugated metal band 13 and a smooth metal band 11.Thus, the holes of the resulting honeycomb are regular in shapes, the manufacturing process is simple, and the combustion is complete and uniform. FIG. 5 shows the honeycomb body formed by laminating the corrugated metal bands 13. FIG. 6 shows the honeycomb body comprising the metal frame.
Preferably, the first surface A14 and/or the second surface B15 of the honeycomb body 10 is covered with a metal mesh 40, and a contact point between the honeycomb body and the metal mesh is fixed by welding. The welding of the honeycomb body 10 and the metal mesh 40 enhances the strength of the infrared device, prevents the deformation and axial movement of the metal bands of the honeycomb body due to the frequent alternation between high and low temperatures, and provides a uniform airflow whereby avoiding backfire.
Preferably, metal wires for forming the metal mesh have a diameter of between 0.01 and 10 mm, and the meshes of the metal mesh are between 2 and 500 per square inch.
Preferably, the metal mesh is formed by coiling and interweaving fine metal fibers irregularly.
Preferably, the honeycomb body 10 has a thickness of between 1 and 100 mm.
Preferably, the metal bands constituting the honeycomb body 10 have a thickness of between 0.01 and 2 mm.
Preferably, the honeycomb body 10 has an opening percentage of between 10 and 95%.
Preferably, the honeycomb body 10 is made of iron-chromium alloy, nickel-chromium alloy, or titanium alloy.
Preferably, the holes or gaps of the honeycomb body 10 are round, square, or hexagonal in shape.

Example 3

A method for manufacturing the infrared device outside the scope of the invention, comprises the following steps:

a)preparing the metal band;
b)laminating or coiling the metal band to form the honeycomb body comprising the plurality of holes; and
c)disposing the through hole on the lateral surface 16 of the honeycomb body, allowing the through hole to penetrate inward through multiple layers of adjacent metal bands, and disposing the metal wire in the through hole for fixing the metal bands.

In contract to an integrated honeycomb, the present honeycomb formed by laminating or coiling the metal bands has a much simple manufacturing process, low manufacturing costs, and high opening percentage.
Preferably, as shown in FIG. 11, upon coiling the metal bands to prepare the honeycomb body, a central hole having a diameter of between 2 and 300 mm is disposed in the middle of the honeycomb body to operate as an airflow channel.
Preferably,after the honeycomb body is prepared, a metal frame is disposed to encircle the central hole and the lateral surface 16whereby fixing the honeycomb body.
Preferably, after the metal frame is disposed, at least one end of the metal wire is fixed on the wire band or the metal frame.
Preferably, as shown in FIG. 9-10, the first surface A and/or the second surface B of the honeycomb body is covered with a metal mesh, or the first surface A and/or the second surface B of the honeycomb body is covered with a metal fiber structure, the metal fiber structure is breathable and presents in the form of fiber mesh, fiber felt, woven mesh, or fiber paper, and a contact point thereof is fixed by welding.

Example 4

A method for manufacturing the infrared device according to the invention comprises the following steps:

a) preparing the metal band;
b) laminating or coiling the metal band to form the honeycomb body comprising the plurality of holes or gaps; and
c) folding said plurality of folding portions onto said top surface (14) and/or said bottom surface (15), and engaging each of said plurality of folding portions with an adjacent one of said plurality of folding portions to form said overlapping embedded member (60).

As an improvement, the method further comprises filling a space formed by embedding the metal bands with a metal material, and fixing the metal material on the metal bands by welding, whereby enhancing the strength of the metal infrared device, and preventing the deformation and axial movement of the metal bands of the honeycomb body due to the frequent alternation between high and low temperatures.
As an improvement, the method further comprises fixing the embedded metal bands by self-melting and welding of the embedded metal bands, whereby achieving the same welding effect as the metal filling material and saving the material cost.
Preferably, upon coiling the metal bands to prepare the honeycomb body, the method further comprises disposing a central hole having a diameter of between 2 and 300 mm in the middle of the honeycomb body to operate as an air flow channel.
Preferably, after the honeycomb is prepared, the method further comprises disposing metal frames to encircle the central hole and the lateral surface 16, respectively, for fixing the honeycomb body.
Preferably, as shown in FIG. 9-10, before or after the embedded member is formed, the first surface A14 and/or the second surface B 15 of the honeycomb body is covered with a metal mesh, or the first surface A and/or the second surface B of the honeycomb body is covered with a metal fiber structure, the metal fiber structure is breathable and presents in the form of fiber mesh, fiber felt, woven mesh, or fiber paper, and a contact point thereof is fixed by welding. The welding of the honeycomb body and the metal mesh or metal fiber structure can effectively enhance the strength of the infrared device and prevent the detachment of the metal mesh or metal fiber structure.
In principle, step A) may be achieved according to one of the following three steps:

1) preparing a corrugated metal band;
2) preparing an integrated metal band comprising a corrugated metal band and a smooth metal band; or
3) preparing an integrated metal band comprising two corrugated metal bands, the holes or gaps being formed between the two corrugated metal bands.

Preferably, the corrugated metal band prepared in step 1) is in the form of undulation, sinusoidal waveform, sawtooth waveform, U-shaped waveform, or rectangular waveform. The metal bands having the above waveforms can form holes having better combustion characteristics.
Thus, when a corrugated metal band or an integrated metal band comprising a corrugated metal band and a smooth metal band is prepared, the metal bands can be laminated or coiled to yield the honeycomb body having holes with regular openings and desired opening percentage.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made within the scope of the appended claims.

Claims

An infrared device for use in a burner, comprising a honeycomb body (10) being in the shape of a cylinder; the honeycomb body (10) comprising a metal band; said metal band being laminated or coiled to yield a plurality of holes; said honeycomb body (10) further comprising a top surface (14) and a bottom surface (15) which are opposite to each other; said plurality of holes penetrating through said top surface (14) and said bottom surface (15); and an outer boundary of said top surface (14) and an outer boundary of said bottom surface (15) being connected whereby yielding a lateral surface (16);
and said metal band comprises a flat band (11) and a corrugated band (13); and said flat band (11) is connected to said corrugated band (13);
characterized in that
said flat band (11) comprises a plurality of folding portions;

said plurality of folding portions is folded onto said top surface (14) and/or said bottom surface (15); and

each of said plurality of folding portions overlaps an adjacent one of said plurality of folding portions to form an overlapping embedded member (60).
The infrared device of claim 1, characterized in that a central hole (12) having a diameter of between 2 and 300 mm is disposed in a middle of said honeycomb body (10) to operate as an air flow channel; and said central hole (12), said lateral surface (16), or the both are encircled by a metal frame.
The infrared device of claim 1, characterized in that a metal material is fixed on said overlapping embedded member (60) by welding.
The infrared device of claim 1, characterized in that said overlapping embedded member (60) is formed and fixed by self-melting and welding of said metal band.
The infrared device of claim 1, characterized in that said overlapping embedded member (60) is formed on said metal band close to an inner or outer boundary of said honeycomb body (10).
The infrared device of claim 1, characterized in that said overlapping embedded member (60) intersects with the whole of the metal band of said honeycomb body (10).
The infrared device of any one of claims 1-6, characterized in that said top surface and/or said bottom surface of said honeycomb body (10) is covered with a metal mesh (40) or a metal fiber structure, said metal fiber structure is breathable and presents in the form of fiber mesh, fiber felt, woven mesh, or fiber paper, and a contact point between said honeycomb body (10) and said metal mesh (40)/said metal fiber structure is fixed by welding.
The infrared device of any one of claims 1-6, characterized in that a thickness between the top surface (14) and the bottom surface (15) is between 1 and 100 mm.
A method for manufacturing the infrared device of claim 1, the method comprising the following steps:
a) preparing said metal band;

b) laminating or coiling said metal band to form said honeycomb body (10) comprising the plurality of holes; and

c) characterized in folding a plurality of folding portions onto said top surface (14) and/or said bottom surface (15), and engaging each of said plurality of folding portions with an adjacent one of said plurality of folding portions to form said overlapping embedded member (60).
The method of claim 9, further comprising covering said top surface (14) and/or said bottom surface (15) with a metal mesh (40) or a metal fiber structure, and welding a contact point between said honeycomb body (10) and said metal mesh (40) or said metal fiber structure, wherein said metal fiber structure is breathable and presents in the form of fiber mesh, fiber felt, woven mesh, or fiber paper.
The method of claim 9, further comprising disposing a central hole (12) having a diameter of between 2 and 300 mm in a middle of said honeycomb body (10) to operate as an air flow channel, and disposing metal frames to encircle said central hole (12) and said lateral surface (16), respectively.
The method of any one of claims 9-11, further comprising fixing a metal material on said overlapping embedded member (60) by welding.
The method of any one of claims 9-11, further comprising fixing said overlapping embedded member (60) by self-melting and welding.
The infrared device of claim 1, characterized in that the corrugated band (13) is in the form of undulation, sinusoidal waveform, sawtooth waveform, U-shaped waveform, or rectangular waveform.